Automated Self-Installing Concrete Formwork

ABSTRACT

The present invention relates to a novel form of concrete formwork for reinforced concrete that relates generally to building construction, and particularly to an improvement to reinforced concrete with an automated self-installing concrete formwork where the system allows all elements required for the concrete pour to be pre-fabricated in a modular way to reduce human error on site and ease speed with which concrete can be being poured onto the rebar for curing.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the xeroxographic reproduction by anyone of the patent document or the patent disclosure in exactly the form it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

BACKGROUND Field of the Invention

The present invention relates generally to building construction, and particularly to an improvement in reinforced concrete with automated self-installing concrete formwork.

Description of the Related Art

Plain concrete does not easily withstand tensile and shear stresses caused by wind, earthquakes, vibrations, and other forces and is therefore unsuitable in most structural applications. In reinforced concrete, the tensile strength of steel and the compressive strength of concrete work together to allow the member to sustain these stresses over considerable spans. Steel is embedded in the concrete in such a manner that the two materials act together to resist those outside forces. The reinforcing steel—rods, bars, or mesh—absorbs the tensile, shear, and sometimes the compressive stresses in a concrete structure. The invention of reinforced concrete in the 19th century revolutionized the construction industry, and concrete became one of the world's most common building materials.

Concrete has low tensile strength but very high compressive strength. Reinforced concrete is created when concrete is combined with steel reinforcing bars that have high tensile strength. The two materials combined act together to resisting forces in a better way than each does by itself. The steel reinforcing bars that are used for this purpose are called “Rebar” as shorthand. Rebar cages are longitudinal or vertical bars that are laid out with uniform spacing and have other sets of rebar placed in a transverse position and attached with ties, clamps or welds. Once rebar cages are installed on a construction site, concrete formwork is assembled to hold concrete in place until it cures enough to hold its own weight. Traditionally, formwork was made out of plywood that is installed by hand, or by reusable metal or plastic concrete formwork that is set up manually, and taken down manually.

The prior methods of setting up concrete formwork in construction are heavily labor intensive, slow, and in the case of formwork made with plywood, not environmentally friendly.

A U.S. Pat. No. 9,683,361B2 prefabricated assemblies which are assembled on a construction site to provide a permanent concrete mold with integrated structural reinforcement and structural splices for cast-in-place concrete structures. The invention enhances the quality of the cast concrete structure while lowering the cost of construction and construction time. Described herein is a column form assembly, a column closure panel assembly, a beam form assembly, and a slab form assembly which are used to construct cast in place structurally reinforced concrete columns, beams, and floor slabs with minimal form work and construction site logistics. Also described herein are a method of assembly of said structures and a method of fabricating said assemblies.

U.S. Pat. No. 10,227,785B2 provides a robotic casting machine (RCM) provides for on-site, or near-site casting and automated production of cast components, such as concrete modular, volumetric building components. The RCM includes stationary and mobile support structures, which can be positioned in a loading configuration, a casting configuration and an ejection configuration in which the cast volumetric component may be ejected from the mold. Tipping machines located beneath the cast component facilitate ejection, rotation and loading of the ejected module onto a transport surface for transport of the module. The support structures are constructed of prefabricated frames that may include at least one standardized section, which may be utilized on every project, and may also include a customized section, which may be provided to achieve desired dimensions of the cast module on a particular project. A casting process is provided in which a volumetric module is cast in a rotated orientation, in which the floor is cast with an initial vertical orientation, the transverse walls extend in a horizontal orientation, which is cast in vertical wall forms, and a longitudinal wall extends horizontally along the top of the mold. Modular, volumetric components created using the RCM and casting process are also described.

A U.S. Pat. No. 9,371,648B1 discloses concrete building structure and method for constructing a building structure which includes a first cross-brace section, including a plurality of pre-cast concrete blocks connected in series by at least one rebar; a second cross-brace section, including a plurality of pre-cast concrete blocks connected in series by at least one rebar, extending generally perpendicularly to the first cross-brace section such that the first and second cross-brace sections form a grid understructure; a plurality of channels encapsulating adjacent blocks from the first and second cross-brace sections, whereby the grid understructure includes channels into which concrete may be poured at a building site; each of the plurality of blocks positioned within respective channels; a plurality of pre-cast concrete slabs resting atop the blocks in the grid understructure; and poured concrete filling each of the channels and a space between adjacent concrete slabs to complete a generally flat floor of the building structure.

A US patent 20160160515A1 describes a construction systems for erecting building structures comprise a plurality of prefabricated interconnectable modular budding units, each unit comprising framing members and a plurality of nodes, each node situated for selective interconnection with other units, the nodes and the exterior dimensions of the frame conforming to ISO shipping standards such that each unit is transportable using the ISO intermodal transportation system, and such that when the units are interconnected, a building structure is formed. The modular units are assembled at a remote location, and are there constructed to a semi-finished state, following which the semi-finished modular units are transported from the remote location to the job site, where they are secured to form the structure being erected, and the semi-finished modular units are thereafter constructed to a finished state.

A U.S. Pat. No. 8,151,537B2 A method of deploying a cooperating set of prefabricated structure comprises positioning a first prefabricated structure including a first shell and a first extension nested within the first shell, the first shell and first extension having corresponding frames that form channels communicating electrical wiring. The method further comprises positioning a second prefabricated structure including a second shell and a second extension nested within the second shell, the second shell and second extension having corresponding frames that form channels communicating electrical wiring. The electrical wiring of the first prefabricated structure and the second prefabricated structure connect so that the first prefabricated structure and the second prefabricated structure share a common electrical system.

An EP patent 0,032,421A1 on fiber-reinforced concrete comprising a concrete matrix including two kinds of short fibers (A,B) one being a short fiber (A) having a Young's modulus higher than that of concrete, the other being a short fiber (B) which has a Young's modulus lower than that of concrete a showing good adhesiveness to concrete. The said fibers are mixed in a predetermined ratio and are dispersed in the concrete matrix. A reinforcing material for concrete is also disclosed, such material consisting of a mixture of the fibers (A.B) as mentioned above.

It can thus be seen from the foregoing that several attempts have been made to provide different materials and strategies for assembling concrete formwork to speed up construction. However clearly, the need exists for an automated self-installing concrete formwork which allows buildings to be built faster and with less construction waste. Automated self-installing concrete formwork are capable of easy, fast, solid installation and can hold the significant weight of concrete and reinforced steel bar (rebar) while concrete cures enough to support its own weight. Furthermore, there is a need for an apparatus and method of manufacture for larger-scale precast concrete blocks which, is substantially automated, easy to use and clean, integrates casting and transportation functions, and is of moderate scale.

None of the previous inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed. Hence, the inventor of the present invention proposes to resolve and surmount existent technical difficulties to eliminate the aforementioned shortcomings of prior art.

SUMMARY

In light of the disadvantages of the prior art, the following summary is provided to facilitate an understanding of some of the innovative features unique to the present invention and is not intended to be a full description. A full appreciation of the various aspects of the invention can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

The primary objective of this invention is to provide improvements with automated self-installing concrete formwork.

It is a further object to eliminate the need for significant hand labor to be necessary to set up formwork on the construction site, as well as significant logistics to require the separate components for formwork to be delivered onto the construction site.

Still another important feature of this invention is in its simplicity to deploy, ease of installation, effectiveness in use and its generally inexpensive cost to use on the construction site.

It is also the objective of the system to provide a wholly automated system for building reinforced concrete buildings, of which this unit is an important component.

Another important object of the present invention is to provide technology which can reduce construction cost and can save time required for construction.

Another objective of the invention is to provide reusable reinforced concrete formwork that can speed up the construction of buildings significantly.

Another objective of the invention is to use Building Imaging Management (BIM) software to guide each piece of formwork to its necessary location and to coordinate with other automated self-installing concrete formwork using cloud robotics.

It is also the objective of invention for concrete formwork to be able to self deinstall after concrete is cured so that it can install itself again in a different location on the same site and allow more reinforced concrete to be poured.

A further object of the present invention is to minimize the manual labor requirements, and its attendant expense, in the installation of any and all reinforced concrete structural members that are used on a construction site.

This Summary is provided merely for purposes of summarizing some example embodiments, so as to provide a basic understanding of some aspects of the subject matter described herein. Accordingly, it will be appreciated that the above-described features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description, Figures, and Claims.

BRIEF DESCRIPTION OF DRAWING

non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following drawings. The system and method of the present invention will now be described with reference to the accompanying flow chart drawing figure, in which:

FIG. 1 is a view that shows the different stages of the invention as it moves onto a construction site under its own power, opens up, and positions itself as per preferred embodiments of the invention. FIG. 1 represents the version that is used for foundation walls.

FIG. 2 is a view that shows the different stages of the invention as it moves onto a construction site under its own power, opens up, and positions itself as per preferred embodiments of the invention. FIG. 2 represents the iteration that is used for vertical columns.

FIG. 3 is a view that shows the different stages of the invention as it moves onto a construction site under its own power, opens up, and positions itself as per preferred embodiments of the invention. FIG. 3 represents the iteration that is used for horizontal floor slabs

FIG. 4 is a view that shows the different stages of the invention as it moves onto a construction site under its own power, opens up, and positions itself as per preferred embodiments of the invention. FIG. 4 represents the iteration that is used for shear walls.

Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the features in the figures may be exaggerated relative to other elements to improve understanding of embodiments of the present invention. The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION

Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.

The present invention relates to an advancement in automated self-installing concrete formwork.

The present invention as per its preferred embodiments provide an automated self-installing concrete formwork that is significantly faster to deploy on the construction site than formwork that is currently available, and is capable of easy, fast, strong installation that can stably handle the weight load of concrete as it cures. The present invention has the follow features for achieving the above object.

The present invention as per its additional embodiments eliminates the need for significant manual labor for installing concrete formwork, as compared with the background art, and can reduce construction cost and can save time required for construction.

The assembly as per its additional embodiments makes it possible to rapidly install concrete.

The assembly as per its additional embodiments, make it possible to construct all foundation and superstructure elements quickly and efficiently in a safer manner and with less danger to people working on the construction site.

The assembly as per its additional embodiments allows the concrete pour to happen faster, and to reduce human error on site that can happen when formwork is being assembled on site from loose components.

FIG. 1 is a view that shows the different stages of the invention as it moves onto a construction site under its own power, opens up, and positions itself. FIG. 1 represents the iteration that is used for foundation walls. The components of the invention are:

-   -   (1) single brushless servo hinge     -   (2) double brushless servo hinge (two hinges back-to-back in a         single housing)     -   (3) metal tube leg prop     -   (4) plywood/plastic composite sheet with coated steel frame         reinforcement     -   (5) metal base chassis     -   (6) battery pack and motor controller     -   (7) retractable wheel that pulls up once unit is set in place         ready for concrete

FIG. 2 is a view that shows the different stages of the invention as it moves onto a construction site under its own power, opens up, and positions itself. FIG. 2 represents the iteration that is used for vertical columns. The components of the invention are:

-   -   (1) single brushless servo hinge     -   (2) double brushless servo hinge (two hinges back-to-back in a         single housing)     -   (3) metal tube leg prop     -   (4) plywood/plastic composite sheet with coated steel frame         reinforcement     -   (5) metal base chassis     -   (6) battery pack and motor controller     -   (7) retractable wheel that pulls up once unit is set in place         ready for concrete

FIG. 3 is a view that shows the different stages of the invention as it moves onto a construction site under its own power, opens up, and positions itself. FIG. 3 represents the iteration that is used for horizontal floor slabs. The components of the invention are:

-   -   (1) single brushless servo hinge     -   (2) double brushless servo hinge (two hinges back-to-back in a         single housing)     -   (3) metal tube leg prop     -   (4) plywood/plastic composite sheet with coated steel frame         reinforcement     -   (5) metal base chassis     -   (6) battery pack and motor controller     -   (7) retractable wheel that pulls up once unit is set in place         ready for concrete

FIG. 4 is a view that shows the different stages of the invention as it moves onto a construction site under its own power, opens up, and positions itself. FIG. 4 represents the iteration that is used for shear walls. The components of the invention are:

-   -   (1) single brushless servo hinge     -   (2) double brushless servo hinge (two hinges back-to-back in a         single housing)     -   (3) metal tube leg prop     -   (4) plywood/plastic composite sheet with coated steel frame         reinforcement     -   (5) metal base chassis     -   (6) battery pack and motor controller     -   (7) retractable wheel that pulls up once unit is set in place         ready for concrete

Having described the invention in detail, those skilled in the art will appreciate that modifications may be made to the invention without departing from its spirit. Therefore, it is not intended that the scope of the invention be limited to the specific embodiment illustrated and described. Rather, it is intended that the scope of this invention be determined by the appended claims and their equivalents.

The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter. 

1: An automated self-installing concrete formwork: speed up the installation of reinforced concrete on the construction site by being self-installing, and automated in their function. 2: An automated self-installing concrete formwork that makes it possible to build houses, buildings and infrastructure faster. 3: An automated assembly regarding self-installing concrete formwork comprising: (1) single brushless servo hinge (2) double brushless servo hinge (two hinges back-to-back in a single housing) (3) metal tube leg prop (4) plywood/plastic composite sheet with coated steel frame reinforcement (5) metal base chassis (6) battery pack and motor controller (7) retractable wheel that pulls up once unit is set in place ready for concrete 